Computer-aided Manufacturing

Yatish, ECE/08/157
603, Parmanand Colony (west), Model Town-I, Delhi-9 Rahul Mehra, ECE/08/139 1026, Sec-14, Sonipat Haryana Shri Balwant Institute of Technology Pallri, Sonipat, Haryana [email protected] [email protected]

INTRODUTION Computer-aided manufacturing (CAM) is the use of computer-based software tools that assist engineers and machinists in manufacturing or prototyping product components and tooling. Its primary purpose is to create a faster production process and components and tooling with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumption. CAM is a programming tool that makes it possible to manufacture physical models designed using computer-aided design (CAD) programs. CAM creates real life versions of components designed within a CAD software package. CAM was first used in 1971 for car body design and tooling. Computer-aided manufacturing (CAM), a form of automation where computers communicate work instructions directly to the manufacturing machinery. The technology evolved from the numerically controlled machines of the 1950s, which were directed by a set of coded instructions contained in a punched paper tape. Today a single computer can control banks of robotic milling machines, lathes, welding machines, and other tools, moving the product from machine to machine as each step in the manufacturing process is completed. Such systems allow easy, fast reprogramming from the computer, permitting quick implementation of design changes. The most advanced systems, which are often integrated with computer-aided design systems, can also manage such tasks as parts ordering, scheduling, and tool replacement. Traditionally, CAM has been considered as a numerical control (NC) programming tool wherein three-dimensional (3D) models of components generated in CAD software are used to generate CNC code to drive numerically controlled machine tools. Although this remains the most common CAM function, CAM functions have expanded to integrate CAM more fully with CAD/CAM/CAE PLM solutions. As with other Computer-Aided technologies, CAM does not eliminate the need for skilled professionals such as Manufacturing Engineers and NC Programmers. CAM, in fact, both leverages the value of the most skilled manufacturing professionals through advanced productivity tools, while building the skills of new professionals through visualization, simulation and optimization tools.

ABSTRACT Computer aids are now affecting most branches and activities of manufacturing industry. Developments such as microprocessors are expected to have a very significant impact, not only on the techniques of controlling manufacturing processes but also on social and economic factors such as the pattern of employment. Computer-aided manufacture has developed out of the field of numerical control of machine tools. There was an early bias towards metal-cutting operations, but more recently there have been significant applications in metal forming, in particular to the design and production of dies, moulds and other forming tools. Current research is leading to the integration of processes and handling systems and to integrated engineering, production and business data processing systems.

APPLICATIONS OF CAM The field of computer-aided design has steadily advanced over the past four decades to the stage at which conceptual designs for new products can be made entirely within the framework of CAD software. From the development of the basic design to the Bill of Materials necessary to manufacture the product there is no requirement at any stage of the process to build physical prototypes. Computer-Aided Manufacturing takes this one step further by bridging the gap between the conceptual design and the manufacturing of the finished product. Whereas in the past it would be necessary for design developed using CAD software to be manually converted into a drafted paper drawing detailing instructions for its manufacture, Computer-Aided Manufacturing software allows data from CAD software to be converted directly into a set of manufacturing instructions.

CAM software converts 3D models generated in CAD into a set of basic operating instructions written in G-Code. G-code is a programming language that can be understood by numerical controlled machine tools essentially industrial robots and the G-code can instruct the machine tool to manufacture a large number of items with perfect precision and faith to the CAD design. Modern numerical controlled machine tools can be linked into a cell, a collection of tools that each performs a specified task in the manufacture of a product. The product is passed along the cell in the manner of a production line, with each machine tool (i.e. welding and milling machines, drills, lathes etc.) performing a single step of the process. For the sake of convenience, a single computer controller can drive all of the tools in a single cell. G-code instructions can be fed to this controller and then left to run the cell with minimal input from human supervisors.

EARLY USE OF CAM The first commercial applications of CAM were in large companies in the automotive and aerospace industries for example UNISURF in 1971 at Renault for car body design and tooling. HISTORICAL SHORCOMINGS

Historically, CAM software was seen to have several shortcomings that necessitated an overly high level of involvement by skilled CNC machinists. Fallows created the first CAM software but this had severe shortcomings and was promptly taken back into the developing stage. CAM software would output code for the least capable machine, as each machine tool interpreter added on to the standard g-code set for increased flexibility. In some cases, such as improperly set up CAM software or specific tools, the CNC machine required manual editing before the program will run properly. None of these issues were so insurmountable that a thoughtful engineer could not overcome for prototyping or small production runs; G-Code is a simple language. In high production or high precision shops, a different set of problems were encountered where an experienced CNC machinist must both hand-code programs and run CAM software.

CAD/CAM/CAE PLM environment requires an effective CAD data exchange. Usually it had been necessary to force the CAD operator to export the data in one of the common data formats, such as IGES or STL, that are supported by a wide variety of software. The output from the CAM software is usually a simple text file of G-code, sometimes many thousands of commands long, that is then transferred to a machine tool using a direct numerical control (DNC) program. CAM packages could not, and still cannot, reason as a machinist can. They could not optimize toolpaths to the extent required of mass production. Users would select the type of tool, machining process and paths to be used. While an engineer may have a working knowledge of g-code programming, small optimization and wear issues compound over time. Mass-produced items that require machining are often initially created through casting or some other nonmachine method. This enables hand-written, short, and highly optimized g-code that could not be produced in a CAM package. At least in the United States, there is a shortage of young, skilled machinists entering the workforce able to perform at the extremes of manufacturing; high precision and mass production. As CAM software and machines become more complicated, the skills required of a machinist advance to approach that of a computer programmer and engineer rather than eliminating the CNC machinist from the workforce.

Integration of CAD with other components of

AREAS OF USAGE Aerospace Engineering Automotive Engineering Mechanical Engineering Medicine Electronic design automation, where CAM tools prepare printed circuit board and integrated circuit design data for manufacturing. Programming of robots. Numerical control for machine tools.

PROBLEMS WITH CAM Unfortunately, there are several limitations of computer-aided manufacturing. Obviously, setting up the infrastructure to begin with can be extremely expensive. Computer-aided manufacturing requires not only the numerical controlled machine tools themselves but also an extensive suite of CAD/CAM software and hardware to develop the design models and convert them into manufacturing instructions as well as trained operatives to run them. Additionally, the field of computer-aided management is fraught with inconsistency. While all numerical controlled machine tools operate using G-code, there is no universally used standard for the code itself. Since there is such a wide variety of machine tools that use the code it tends to be the case that manufacturers create their own bespoke codes to operate their machinery. While this lack of standardisation may not be a problem in itself, it can become a problem when the time comes to convert 3D CAD designs into G-code. CAD systems tend to store data in their own proprietary format (in the same way that word processor applications do), so it can often be a challenge to transfer data from CAD to CAM software and then into whatever form of G-code the manufacturer employs.

BENEFITS OF CAM While undesirable for factory workers, the ideal state of affairs for manufacturers is an entirely automated manufacturing process. In conjunction with computer-aided design, computer-aided manufacturing enables manufacturers to reduce the costs of producing goods by minimising the involvement of human operators. In addition to lower running costs there are several additional benefits to using CAM software. By removing the need to translate CAD models into manufacturing instructions through paper drafts it enables manufactures to make quick alterations to the product design, feeding updated instructions to the machine tools and seeing instant results. In addition, many CAM software packages have the ability to manage simple tasks such as the reordering of parts, further minimising human involvement. Though all numerical controlled machine tools have the ability to sense errors and automatically shut down, many can actually send a message to their human operators via mobile phones or e-mail, informing them of the problem and awaiting further instructions. All in all, CAM software represents a continuation of the trend to make manufacturing entirely automated. While CAD removed the need to retain a team of drafters to design new products, CAM removes the need for skilled and unskilled factory workers. All of these developments result in lower operational costs, lower end product prices and increased profits for manufacturers.